Transport tool

ABSTRACT

A transportation tool for transporting a single composite aircraft fuselage section, including a first spindle weldment mounted on a first structural tower, and a second spindle weldment mounted on a second structural tower and configured to couple the single composite aircraft fuselage section to the structural towers. A first gimbal assembly configured to allow the first spindle weldment to move independent of the first structural tower, and a second gimbal assembly configured to allow the second spindle weldment to move independent of the second structural tower.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to a tool used for handling multiple lengthcomposite fuselage sections with integrated related tooling and used toassist with trim and Non Destructive Inspection (NDI) operations.

2. Background

Aircraft manufacturing technology has advanced to the state where thecreation of a very large one piece aircraft composite fuselage sectioncreating load requirements of near 50,000 lbs is possible.

These unique airplane fuselage sections have driven a need for properhandling equipment. For example, in test programs for large aircraftcomposite fuselage sections, a need has arisen for a tool capable ofsupporting, positioning and transporting large composite fuselagesections of varying lengths, while the sections are integrated withlayup tools and internal support tooling. The sections must be supportedand positioned while being transported throughout a factory and whilebeing moved in and out of an autoclave. Heretofore, such large transporttools were not necessary since the manufacture of large compositefuselage sections was not done.

SUMMARY OF THE INVENTION

The present invention provides a tool capable of supporting, positioningand transporting large composite fuselage sections of varying lengths.Moreover, the tool of the present invention is capable of supporting,positioning and transporting the sections throughout a factory and whilebeing moved in and out of an autoclave, with integrated layup tools andinternal support tooling.

In an aspect of the invention, a transportation tool is provided whichincludes a first structural tower, and a second structural tower. Afirst structural frame member and a second structural frame member areused to secure the first structural tower to the second structural towerto support a payload. The first and second structural frame membersdefine vacuum chamber accumulators.

In another aspect of the invention, a transportation tool is providedfor transporting a single composite aircraft fuselage section. The toolincludes a first spindle weldment mounted on a first structural tower,and a second spindle weldment mounted on a second structural tower, thespindle weldments are configured to couple the single composite aircraftfuselage section to the first and second structural towers. Alsoincluded is a first gimbal assembly configured to allow the firstspindle weldment to move independent of the first structural tower, anda second gimbal assembly configured to allow the second spindle weldmentto move independent of the second structural tower. The tool furtherincludes a first structural frame member and a second structural framemember for securing the first structural tower to the second structuraltower. The first and second structural frame members define vacuumchamber accumulators.

In yet another aspect of the invention, a method is provided formanufacture of a one-piece composite aircraft fuselage which includesloading a composite fuselage into a support structure; performing vacuumbagging operations on the composite fuselage; and maintaining vacuumintegrity of the bagged composite fuselage for processing in anautoclave using vacuum accumulators integrated into the supportstructure.

Additional objects and features of the invention will be set forth inpart in the detailed description which follows. It is to be understoodthat both the foregoing general description and the following detaileddescription are merely exemplary of the invention, and are intended toprovide an overview or framework for understanding the nature andcharacter of the invention as it is claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are included to provide further understandingof the invention, illustrate various embodiments of the invention, andtogether with the description serve to explain the principles andoperation of the invention. In the drawings, the same components havethe same reference numerals. The illustrated embodiment is intended toillustrate, but not to limit the invention. The drawings include thefollowing Figures:

FIG. 1 is a support, position and transport tool for a large payload inaccordance with an embodiment of the present invention;

FIG. 2 is an exploded view of the tool of FIG. 1 in accordance with anembodiment of the present invention;

FIG. 3 is an exploded view of a component of the tool of FIG. 1 inaccordance with an embodiment of the present invention;

FIGS. 4A and 4B are perspective views of the first and second towers inaccordance with an embodiment of the present invention;

FIG. 5 is a detailed perspective view of a tower of the transport toolof FIG. 1 in accordance with an embodiment of the present invention; and

FIG. 6 is an illustration of a removable disk brake in use with a drivesystem in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 is an illustration of a multi-use transport tool 100 or cartcreated to support, position and transport a payload 102, with acapacity of approximately 50,000 lbs. In one embodiment, payload 102includes a composite fuselage section of an aircraft and may furtherinclude integrated layup and support tooling. As an example of thecapacity of tool 100, payload 102 may be a payload up to 42 ft long witha diameter of about 20 ft.

Payload 102 is manufactured using well known composite manufacturingtechniques using tape layup processes that require the use of anautoclave to cure the composite material. Accordingly, tool 100 iscapable of enduring adverse environments such as those generated by anautoclave, for example, elevated temperature of 450 degrees F. andelevated pressures of 90 psi. Tool 100 may be used to support andtransport payload 102 from an area including a tape layup machine to anarea housing the autoclave. Tool 100 may be required to support payload102 in the environment created by the autoclave for the duration of acure cycle. Tool 100 may then be used to transport payload 102 tonon-destructive inspection (NDI) and Trim area.

After tool 100 has been used to support payload 102 throughout thecomposite layup and curing process, tool 100 may then be used inconjunction secondary support tooling to transport payload 102 to alocation which may be, for example, as far as two miles away. Asdescribed below, tool 100 includes features to minimize deflection inpayload 102 caused by dynamic load effects experienced during the entiretransport sequence.

FIG. 2 is an exploded view of tool 100 in accordance with an embodimentof the present invention. In one embodiment, tool 100 includes firsttower 202, second tower 204, first side rail 206, second side rail 208,free end spindle weldment 210, geared end spindle weldment 212, free endgimbal assembly 214, and geared end gimbal assembly 216. Thetransportation function of tool 100 is facilitated with eight swivelcasters 218, twelve autoclave casters 220, a pneumatic powered drivesystem 222 and a pneumatic disk brake system 224 with pneumaticcontrols.

The supported payload 102 indexes to spindle weldments 210 and 212 witha receptacle 302 (FIG. 3) that captures a spherical hub (not shown). Asshown in FIG. 1, generally, the hub along with mandrel 104 is made anintegrated part of payload 102 and thus is common among different typesof payloads.

After indexing payload 102, mandrel 104, supporting payload 102, andtool 100 may then be bolted at spindle weldments 210 and 212, forexample, along the bolt pattern 304 shown in FIG. 3.

As shown in FIGS. 4A, 4B and 5, spindle weldments 210 and 212 each reston gimbal assemblies 214 and 216, respectively. Each gimbal assembly 214and 216 is supported by structural first tower 202 and second tower 204.Towers 202 and 204 can be made of any suitable material, preferablysteel.

Tool 100 experiences various transportation routes. For example, theuncured payload 102 is transported from the layup area to the cure area.The post cure payload 102 is transported from the cure area to the trim,test and assembly area. The trimmed payload 102 is transported from thetrim/assembly area across roadways (which can include railroad tracks)to various other locations, such as a paint hanger. All of these movescause payload 102 to experience dynamic effects created by rough anduneven surfaces. As a result, the relative position of first tower 202and second tower 204 see movement, deflection, racking and vibration.Undesirable loads, deflections, racking or vibrations can be transferredinto and become detrimental to the production payload 102. For example,wrinkles may develop in the pre-cured payload 102 when moving it fromthe layup area to the cure area.

In accordance with an embodiment of the present invention, gimbalassemblies 214 and 216 are incorporated into tool 100 to reduce theeffect of the undesirable loads. Gimbal assemblies 214 and 216 minimizeinduced deflections of the pre-cured and post cured payload 102 (i.e.composite fuselage section) as well as provide bearings for support androtation.

Gimbal assemblies 214 and 216 allow payload 102 to be supportedindependent of the deflections experienced by tool 100. Gimbalassemblies 214 and 216 allow payload 102 and spindle weldments 210 and212 to rotate about longitudinal axis 502 x, lateral horizontal axis 502y, and vertical axis 502 z using, for example, a set of roller bearings.

As best illustrated in FIG. 5 with regard to gimbal assembly 214, eachgimbal assembly 214 and 216 may be repositioned as indicated by arrow506 to an elevated height H. Height H may range from 0 ft to about 3 ft.To move gimbal assemblies 214 and 216 along arrow 506, payload 102 mustbe removed. With the main load removed, gimbal assemblies 214 and 216are lifted to expose a portion of column 508. A pin 510 is positionedthrough column 508 to hold column 508 at the elevated position H. Theability to raise and lower gimbal assemblies 214 and 216 assists NDI,bagging and trimming operations.

As shown in FIGS. 3, 4A and 6, spindle weldment 212 on first tower 202at the drive end of tool 100 is coupled to drive system 222 thatcontrols longitudinal rotation of payload 102.

In one embodiment, drive system 222 is pneumatically powered. Forexample, drive system 222 may operate with shop supplied air routed thrua control box. In one embodiment, as shown in FIG. 3, load may betransmitted by an air motor 306 and a series of chain driven gears 308.In one embodiment, through a particular arrangement of gears, motor 306can generate an output beyond 8300 ft-lbs of torque.

In one embodiment, drive system 222 rotates payload 102 both in theclockwise and counterclockwise directions. When motor 306 is powered“on”, pneumatic disk brake 602 is disengaged.

When motor 306 is powered “off”, pneumatic disk brake 602 engages. Oncepayload 102 comes to rest, pneumatic disk brake 602 prevents payload 102from any undesirable rotation. In one embodiment, disk brake 602 mayresist up to 16600 ft-lbs of torque, including mandated factors ofsafety. In one embodiment, air motor 306 and disk brake 602 areremovable from tool 100 so that air motor 306 and disk brake 602 may notbe exposed to the autoclave environment. Once the autoclave operationsare complete, motor 306 and brake 602 may be reinstalled.

In one operational example, the power and braking systems may beexpected to turn and stop an unbalanced payload 102 of up to 8,333ft-lbs of torque. In this example, payload 102 is a composite fuselagesection. Due to layup tool manufacturing and layup variability, a 50 kipload could vary from the theoretical axis of rotation by up to 2 in.Also; different geometries of fuselage sections can add to thegeneration of off balanced loads. The integrated power and brakingsystems, reduce the risk to personnel and property.

It is undesirable for an unbalanced payload 102 to spool freely. Theprevention of spooling may be controlled by applying back pressure tothe air motor. However, air motors that withstand the amount of loadcontemplated in this example are not known to be available.

Since the system is pneumatically powered, it functions such that whenthe air is on, motor 306 turns and brake 602 is disengaged. In oneembodiment, to power air motor 306 an operator must physically hold thecontrol knob to an “on” position. When the air is off, motor 306 ceasesoperation and a spring loaded brake 602 is applied. Brake 602 isdisengaged with air pressure and engaged by releasing the air pressurein order to activate the spring mechanism.

Alternatively, a set of lock pins as shown in FIG. 4B, one per tower 202and 204, may be inserted through bearing assemblies on gimbal assemblies214 and 216 to serve as a backup to brake 602 for prevention of rotationduring stationary operations. In one embodiment, the lock pin andhousing are engineered to resist over 41600 ft-lbs of torque includingmandated factors of safety. Additionally, the lock pins serve the samefunction for ground transportation operations. The pins are installedand removed manually.

As shown in FIG. 4B, spindle weldment 210 on second tower 204 at thefree end of tool 100 rests on bearings and allows for longitudinalrotation. Spindle weldment 210 also allows for longitudinal translation,which may be caused by thermal expansion resulting from the heatexperienced during the autoclave cure cycle.

As shown in FIGS. 2, 4A and 4B, first tower 202 and second tower 204 arejoined together by first side rail 206, second side rail 208 andfasteners 410. In one embodiment, hollow side rails 206 and 208 serve asvacuum chambers (negative pressure accumulators) to maintain vacuumpressure to payload 102, such as a bagged pre-cured composite fuselagesections. Side rails 206 and 208 are equipped with the proper fittingsto connect vacuum hoses.

Typically, vacuum accumulators are a separate independent systemattached to transport tools. In accordance with the present invention,integrated parts of tool 100, namely hollow side rails 206 and 208, areused as vacuum accumulators. This adaptation reduces tooling costs.

Vacuum accumulators 206 and 208 are used to hold vacuum on baggedpayload 102 while payload 102 is being transported, for example, fromthe layup area to the curing area. The integrated vacuum system may alsobe used after cure to transport payload 102 to the NDI and trim area.

If vacuum loss should occur during transport, pieces of payload 102,such as caul plates and the like could dislodge and cause significantdamage.

In one embodiment, once all air is pumped out of side rail chambers 206and 208, hoses are disconnected from valves leaving side rail chambers206 and 208, now charged with negative pressure. When needed in thetransport process, hoses can be reconnected from side rail chambers 206and 208 to bagged payload 102. In this embodiment, bagged payload 102has previously had all air evacuated from it and sealed. When baggedpayload 102 is connected via the hoses to side rail chambers 206 and208, the valves are opened so that the vacuum pressure in side railchambers 206 and 208 is transferred to bagged payload 102. In thismanner, vacuum pressure can be maintained on bagged payload 102 suchthat any leaking in the bag system is overcome and bagged payload 102can be safely held together and transported.

As best shown in FIGS. 4A and 4B, for ground transportation, each tower202 and 204 has four spring loaded swivel casters 218.

To shuttle payload 102 in and out of the autoclave, spring loaded swivelcasters 218 are removed from each tower 202 and 204. Towers 202 and 204are equipped with jack support points to raise and lower the towers.Using the jack supports, tool 100 is lowered on to a different set ofcasters 220, referred to as autoclave casters 220. Each tower 202 and204 can have at least six autoclave casters 220. Each autoclave casters220 may have a raised ridge circumventing the caster which coordinatesto recessed floor mounted steel tracks.

Again referring to FIGS. 4A and 4B, each tower 202 and 204 may beequipped with a tow bar 412. Tow bar 412 is used to connect theassembled tool 100 to a tug or fork truck. One tow bar may be used forlongitudinal towing and the other attached to the side for lateralpositioning.

Accordingly, the scope of the present invention should not be limited tothe particular embodiments illustrated and described herein, as they aremerely exemplary in nature, but rather, should be fully commensuratewith that of the claims appended hereafter and their functionalequivalents.

1. A transportation tool comprising: a first structural tower; a secondstructural tower; a first structural frame member and a secondstructural frame member securing said first structural tower to saidsecond structural tower to support a payload; said first and secondstructural frame members defining vacuum chamber accumulators.
 2. Thetool of claim 1, wherein said first and second structural frame membersmaintain vacuum integrity of a payload bagged for processing in anautoclave.
 3. The tool of claim 1, wherein said payload comprises a onepiece composite fuselage section.
 4. The tool of claim 1, furthercomprising casters for use on tracks.
 5. The tool of claim 1, furthercomprising casters for non-track use.
 6. The tool of claim 1, furthercomprising a first spindle weldment mounted on the first structuraltower and a second spindle weldment mounted on the second structuraltower for coupling the payload to the first and second structuraltowers.
 7. The tool of claim 1, further comprising a first gimbalassembly mounted on the first structural tower and a second gimbalassembly mounted on the second structural tower, the first and secondgimbal assemblies configured to allow the payload to move independent ofthe first and second structural towers.
 8. The tool of claim 7, whereinthe first and second gimbal assemblies are each mounted on a moveablecolumn configured to raise and lower the gimbal assemblies.
 9. The toolof claim 1, further comprising a drive system configured to rotate thepayload.
 10. The tool of claim 1, further comprising a brake systemconfigured to keep the payload stationary.
 11. The tool of claim 10,wherein said brake system further comprises pins that lock the payloadin the stationary position.
 12. A transportation tool for transporting asingle composite aircraft fuselage section comprising: a first spindleweldment mounted on a first structural tower; a second spindle weldmentmounted on a second structural tower, the spindle weldments configuredto couple the single composite aircraft fuselage section to the firstand second structural towers; a first gimbal assembly configured toallow the first spindle weldment to move independent of the firststructural tower; a second gimbal assembly configured to allow thesecond spindle weldment to move independent of the second structuraltower; and a first structural frame member and a second structural framemember securing said first structural tower to said second structuraltower to support, said first and second structural frame membersdefining vacuum chamber accumulators.
 13. The tool of claim 12, whereinsaid first and second structural frame members maintain vacuum integrityof a bagged single composite aircraft fuselage section for processing inan autoclave.
 14. The tool of claim 12, further comprising casters foruse on tracks.
 15. The tool of claim 12, further comprising casters fornon-track use.
 16. The tool of claim 12, wherein the first and secondgimbal assemblies are each mounted on a moveable column configured toraise and lower the gimbal assemblies.
 17. The tool of claim 12, furthercomprising a drive system configured to rotate the single compositeaircraft fuselage section when mounted in the tool.
 18. The tool ofclaim 12, further comprising a brake system configured to decelerate therotation and hold the single composite aircraft fuselage sectionstationary when mounted in the tool.
 19. The tool of claim 18, whereinsaid brake system further comprises pins that lock the single compositeaircraft fuselage section in the stationary position when mounted in thetool.
 20. A method for manufacture of one-piece composite aircraftfuselages, comprising: loading a composite fuselage into a supportstructure; performing vacuum bagging operations on the compositefuselage; and maintaining vacuum integrity of the bagged compositefuselage for processing in an autoclave using vacuum accumulatorsintegrated into the support structure.